An apparatus comprises a sensor circuit configured to detect activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler. An analog up/down timer circuit has an input coupled to an output of the sensor circuit and generates a variable threshold signal that varies as a function of an activation time of the at least one circulator. A burner control circuit receives the variable threshold signal from the analog up/down timer circuit and generates an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal. An ignition driver receives the ignition control signal from the burner control circuit and generates an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal.
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1. An apparatus comprising: a sensor circuit configured to detect activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler; an analog up/down timer circuit having an input coupled to an output of the sensor circuit and configured to generate a variable threshold signal that varies as a function of an activation time of said at least one circulator; a burner control circuit configured to receive the variable threshold signal from the analog up/down timer circuit and to generate an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and an ignition driver configured to receive the ignition control signal from the burner control circuit and to generate an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal; wherein said at least one circulator comprises a plurality of circulators; and wherein the analog up/down timer circuit is configured to generate the variable threshold signal at least in part by being configured: to charge a charge storage element in a charge mode of operation for a period of time for which at least one of the plurality of circulators is activated; and to discharge the charge storage element in a discharge mode of operation for a period of time for which none of the plurality of circulators is activated.
A boiler control system includes a sensor to detect when circulator pumps are moving liquid from the boiler through heating loops. An analog timer circuit, connected to the sensor, generates a variable threshold signal. This threshold changes based on how long the circulator pumps have been running. A burner control circuit compares the boiler temperature with this threshold signal and generates an ignition signal. An ignition driver then uses this signal to control the burner, which heats the boiler liquid. The analog timer increases the threshold voltage while at least one pump is active and decreases the threshold voltage when all pumps are inactive by charging and discharging a capacitor.
2. The apparatus of claim 1 wherein the analog up/down timer circuit comprises: a pulse source; the charge storage element; a charge pump coupled between the pulse source and the charge storage element; and a discharge pump coupled between the pulse source and the charge storage element; wherein a pulse signal generated by the pulse source is utilized to charge the charge storage element via the charge pump in a charge mode of operation for a period of time for which at least one of the plurality of circulators is activated and to discharge the charge storage element via the discharge pump in a discharge mode of operation for a period of time for which none of the plurality of circulators is activated.
The boiler control system's analog timer circuit (as described in the previous claim) contains a pulse source, a charge storage element (capacitor), a charge pump, and a discharge pump. The pulse source drives both pumps. When at least one circulator pump is active, the charge pump uses pulses to charge the capacitor. When no circulator pumps are active, the discharge pump uses pulses to discharge the capacitor. The voltage across the capacitor serves as the variable threshold signal which reflects the circulator pump activation time.
3. The apparatus of claim 2 wherein the analog up/down timer circuit is configured in a particular one of the charge and discharge modes of operation responsive to an up/down control signal generated by the sensor circuit.
In the boiler control system, the analog timer circuit described previously uses an up/down control signal from the sensor circuit to switch between charging and discharging modes. When the sensor indicates at least one circulator pump is running, the timer charges the capacitor. When the sensor indicates no pumps are running, the timer discharges the capacitor. The up/down control signal therefore determines whether the charge pump or discharge pump is actively driven by the pulse source, thereby setting the mode of the timer circuit.
4. The apparatus of claim 2 wherein the charge pump and the discharge pump are driven by respective ones of complemented and uncomplemented versions of the pulse signal generated by the pulse source.
In the boiler control system, the charge and discharge pumps within the analog timer circuit (as described previously) are controlled by the pulse signal and its inverse (complemented version). The charge pump is driven by either the original or complemented pulse signal and the discharge pump is driven by the opposite signal. This ensures that only one pump is actively charging or discharging the capacitor at any given time, preventing simultaneous operation.
5. The apparatus of claim 2 wherein the analog up/down timer circuit further comprises: a charge distribution circuit coupled between the charge pump and the charge storage element; wherein the charge distribution circuit comprises first and second circuit paths separating energy from the charge pump into respective first and second portions; the first circuit path providing the first portion of the charge pump energy to the charge storage element; and the second circuit path diverting the second portion of the charge pump energy away from the charge storage element.
In the boiler control system, a charge distribution circuit is added between the charge pump and charge storage element (capacitor) of the analog timer (as described previously). This circuit splits the charge pump's output energy into two paths: one path sends charge to the capacitor, while the other path diverts charge away from the capacitor. By controlling the proportion of charge going to each path, the charging rate of the capacitor can be adjusted.
6. The apparatus of claim 2 wherein the analog up/down timer circuit further comprises: a discharge distribution circuit coupled between the discharge pump and the charge storage element; wherein the discharge distribution circuit comprises first and second circuit paths separating energy from the discharge pump into respective first and second portions; the first circuit path providing the first portion of the discharge pump energy to the charge storage element; and the second circuit path diverting the second portion of the discharge pump energy away from the charge storage element.
In the boiler control system, a discharge distribution circuit is added between the discharge pump and charge storage element (capacitor) of the analog timer (as described previously). This circuit splits the discharge pump's output energy into two paths: one path allows charge to flow from the capacitor to the discharge pump, while the other path diverts charge to ground. By controlling the proportion of charge going to each path, the discharging rate of the capacitor can be adjusted.
7. The apparatus of claim 1 further comprising a dual boiler sense circuit, the dual boiler sense circuit comprising: a first temperature sensor configured to generate the temperature sensor signal as a first temperature sensor voltage; and a second temperature sensor configured to generate a second temperature sensor voltage.
The boiler control system further includes a dual boiler sense circuit. This circuit uses two temperature sensors. The first sensor generates a first voltage representing the boiler temperature, and the second sensor generates a second voltage also representing the boiler temperature. These two temperature readings provide redundancy and allow for fault detection.
8. The apparatus of claim 7 further comprising a fault detection circuit configured to monitor the first and second temperature sensor voltages and to generate a fault indication signal if the first and second temperature sensor voltages differ from one another by more than a designated amount.
The boiler control system described previously includes a fault detection circuit. This circuit monitors the two temperature sensor voltages generated by the dual boiler sense circuit. If the difference between the two voltages exceeds a certain threshold, the fault detection circuit generates a fault indication signal. This signal indicates a potential sensor malfunction or a significant temperature discrepancy within the boiler.
9. An apparatus comprising: a sensor circuit configured to detect activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler; an analog up/down timer circuit having an input coupled to an output of the sensor circuit and configured to generate a variable threshold signal that varies as a function of an activation time of said at least one circulator; a burner control circuit configured to receive the variable threshold signal from the analog up/down timer circuit and to generate an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and an ignition driver configured to receive the ignition control signal from the burner control circuit and to generate an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal; wherein said at least one circulator comprises a plurality of circulators and the sensor circuit comprises a current sense circuit arranged in series with respective alternating-current control lines of the plurality of circulators.
A boiler control system includes a sensor to detect when circulator pumps are moving liquid from the boiler through heating loops. The sensor uses a current sense circuit to monitor the AC power lines of the pumps. An analog timer circuit, connected to the sensor, generates a variable threshold signal. This threshold changes based on how long the circulator pumps have been running. A burner control circuit compares the boiler temperature with this threshold signal and generates an ignition signal. An ignition driver then uses this signal to control the burner, which heats the boiler liquid.
10. An apparatus comprising: a sensor circuit configured to detect activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler; an analog up/down timer circuit having an input coupled to an output of the sensor circuit and configured to generate a variable threshold signal that varies as a function of an activation time of said at least one circulator; a burner control circuit configured to receive the variable threshold signal from the analog up/down timer circuit and to generate an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and an ignition driver configured to receive the ignition control signal from the burner control circuit and to generate an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal; wherein the ignition driver comprises a first relay circuit configured to control a state of a first switch arranged in series with an alternating-current control line of the burner based at least in part on the ignition signal.
A boiler control system includes a sensor to detect when circulator pumps are moving liquid from the boiler through heating loops. An analog timer circuit, connected to the sensor, generates a variable threshold signal. This threshold changes based on how long the circulator pumps have been running. A burner control circuit compares the boiler temperature with this threshold signal and generates an ignition signal. An ignition driver, which controls the burner, contains a relay that switches the AC power line to the burner on and off, based on the ignition signal from the burner control circuit.
11. The apparatus of claim 10 further comprising a fault driver comprising a second relay circuit configured to control a state of a second switch arranged in series with the first switch and the alternating-current control line of the burner based at least in part on a fault indication signal generated by a fault detection circuit.
The boiler control system described previously includes a fault driver and a fault detection circuit. The fault driver contains a second relay that controls a second switch in series with the burner's AC power line. The fault detection circuit generates a fault signal if something is wrong. The fault driver opens the second switch when it receives a fault signal, providing a failsafe mechanism to shut down the burner in case of a detected fault, in addition to the first relay.
12. A method comprising: detecting activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler; generating a variable threshold signal that varies as a function of an activation time of said at least one circulator; generating an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and generating an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal; wherein said at least one circulator comprises a plurality of circulators and generating the variable threshold signal comprises: charging a charge storage element in a charge mode of operation for a period of time for which at least one of the plurality of circulators is activated; and discharging the charge storage element in a discharge mode of operation for a period of time for which none of the plurality of circulators is activated.
A method for controlling a boiler includes detecting when circulator pumps are moving liquid from the boiler through heating loops. An analog timer generates a variable threshold signal that changes based on how long the circulator pumps have been running. A burner control signal is generated by comparing the boiler temperature to this threshold. An ignition signal is then generated for the burner. The analog timer increases the threshold voltage while at least one pump is active and decreases the threshold voltage when all pumps are inactive by charging and discharging a capacitor.
13. The method of claim 12 wherein the charge storage element is charged via a charge pump in the charge mode of operation and the charge storage element is discharged via a discharge pump in the discharge mode of operation.
The boiler control method described previously involves charging a charge storage element (capacitor) in the analog timer using a charge pump when at least one circulator pump is running. When no circulator pumps are running, a discharge pump is used to discharge the capacitor. The charging and discharging action is controlled by detecting when the circulator pumps are on or off, allowing the system to adjust the burner based on heating demand.
14. The method of claim 12 further comprising: generating the temperature sensor signal as a first temperature sensor voltage indicative of a temperature of the liquid in the boiler; and generating a second temperature sensor voltage also indicative of a temperature of the liquid in the boiler.
The boiler control method includes generating a first voltage signal representing the boiler temperature using a first temperature sensor. A second, redundant voltage signal representing the boiler temperature is generated using a second temperature sensor. Using two sensors provides redundancy and allows the system to detect sensor failures or temperature discrepancies.
15. The method of claim 14 further comprising: monitoring the first and second temperature sensor voltages; and generating a fault indication signal if the first and second temperature sensor voltages differ from one another by more than a designated amount.
The boiler control method involves monitoring the first and second voltage signals representing the boiler temperature, as described previously. If the difference between these two voltage signals exceeds a predefined limit, a fault indication signal is generated. This signal alerts the system to a potential problem with the temperature sensors or a temperature anomaly within the boiler.
16. A method comprising: detecting activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler; generating a variable threshold signal that varies as a function of an activation time of said at least one circulator; generating an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and generating an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal; wherein said at least one circulator comprises a plurality of circulators and detecting activation of at least one circulator comprises sensing current in respective alternating-current control lines of the plurality of circulators.
A method for controlling a boiler includes detecting when circulator pumps are moving liquid from the boiler through heating loops by measuring the current in the AC power lines of the pumps. An analog timer generates a variable threshold signal that changes based on how long the circulator pumps have been running. A burner control signal is generated by comparing the boiler temperature to this threshold. An ignition signal is then generated for the burner.
17. A method comprising: detecting activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler; generating a variable threshold signal that varies as a function of an activation time of said at least one circulator; generating an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; generating an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal; and controlling a state of a first switch arranged in series with an alternating-current control line of the burner based at least in part on the ignition signal.
A method for controlling a boiler includes detecting when circulator pumps are moving liquid from the boiler through heating loops. An analog timer generates a variable threshold signal that changes based on how long the circulator pumps have been running. A burner control signal is generated by comparing the boiler temperature to this threshold. An ignition signal is then generated for the burner. The state of a switch in series with the burner's AC power line is controlled based on the generated ignition signal.
18. The method of claim 17 further comprising controlling a state of a second switch arranged in series with the first switch and the alternating-current control line of the burner based at least in part on a fault indication signal.
This invention relates to gas burner control systems, specifically addressing fault detection and mitigation in alternating-current (AC) control lines. The system includes a first switch connected in series with the AC control line of a gas burner, where the switch regulates the burner's operation. The improvement involves a second switch also arranged in series with the first switch and the AC control line. The second switch is controlled based on a fault indication signal, which may originate from a fault detection mechanism monitoring the system. When a fault is detected, the second switch can be activated to interrupt or modify the AC control line's operation, enhancing safety and reliability. The fault indication signal may be generated by sensors, circuit monitors, or other diagnostic components within the system. This dual-switch configuration allows for redundant control, ensuring that faults in the primary control path do not compromise burner safety. The invention is particularly useful in industrial or residential gas appliances where reliable fault handling is critical. The system may also include additional features such as feedback mechanisms to confirm the state of the switches or the presence of a fault. The overall goal is to improve the robustness of gas burner control systems by providing an additional layer of fault management.
19. A heating system comprising: a boiler; a burner configured to burn fuel to heat liquid in the boiler; at least one circulation loop; at least one circulator configured to circulate liquid from the boiler through said at least one circulation loop and back to the boiler; a sensor circuit configured to detect activation of said at least one circulator; an analog up/down timer circuit having an input coupled to an output of the sensor circuit and configured to generate a variable threshold signal that varies as a function of an activation time of said at least one circulator; a burner control circuit configured to receive the variable threshold signal from the analog up/down timer circuit and to generate an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and an ignition driver configured to receive the ignition control signal from the burner control circuit and to generate an ignition signal for the burner based at least in part on the ignition control signal; wherein said at least one circulator comprises a plurality of circulators; and wherein the analog up/down timer circuit is configured to generate the variable threshold signal at least in part by being configured: to charge a charge storage element in a charge mode of operation for a period of time for which at least one of the plurality of circulators is activated; and to discharge the charge storage element in a discharge mode of operation for a period of time for which none of the plurality of circulators is activated.
A heating system includes a boiler, a burner to heat liquid in the boiler, and circulator pumps to circulate the heated liquid through heating loops. A sensor detects when the circulator pumps are running. An analog timer, connected to the sensor, generates a variable threshold signal that changes based on how long the circulator pumps have been running. A burner control circuit compares the boiler temperature with this threshold signal and generates an ignition signal. An ignition driver then uses this signal to control the burner. The analog timer increases the threshold voltage while at least one pump is active and decreases the threshold voltage when all pumps are inactive by charging and discharging a capacitor.
20. The system of claim 19 wherein the analog up/down timer circuit comprises: a pulse source; the charge storage element; a charge pump coupled between the pulse source and the charge storage element; and a discharge pump coupled between the pulse source and the charge storage element; wherein a pulse signal generated by the pulse source is utilized to charge the charge storage element via the charge pump in a charge mode of operation for a period of time for which at least one of the plurality of circulators is activated and to discharge the charge storage element via the discharge pump in a discharge mode of operation for a period of time for which none of the plurality of circulators is activated.
The heating system's analog timer circuit (as described in the previous claim) contains a pulse source, a charge storage element (capacitor), a charge pump, and a discharge pump. The pulse source drives both pumps. When at least one circulator pump is active, the charge pump uses pulses to charge the capacitor. When no circulator pumps are active, the discharge pump uses pulses to discharge the capacitor. The voltage across the capacitor serves as the variable threshold signal which reflects the circulator pump activation time.
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February 5, 2016
April 25, 2017
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